Image source unit and image display unit

ABSTRACT

The present invention is to provide an image source unit for improving use efficiency of the image light and also provide an image display unit comprising the image source unit. 
     The image source unit  4  comprising: an image light source  5 ; and an optical sheet  10  laminated on the image light source, the optical sheet comprising: a base material layer  11 ; and an optical functional layer  12  formed on the image light source side surface of the base material layer, the optical functional layer comprising: light-transmissive portions  13  arranged parallel along the sheet face; and light-absorbing portion(s)  14  arranged between the light-transmissive portions, the image light source side face of the light-transmissive portion having protrusions  17  each having a curved or polygonal line so that the protrusions project towards the image light source side in cross section in the sheet-thickness direction.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to an image source unit and an imagedisplay unit comprising the image source unit.

2. Description of the Related Art

An image display unit which projects an image to the observer side isprovided with an image source unit comprising: an image light source;and an optical sheet comprising a layer having various functions forraising the quality of image light emitted from the image light sourceand projecting the image to the observer side.

For example, in a case of a plasma display as one of the image displayunits, when the observer side is bright, the contrast of the display isinsufficient and thereby the quality of the image is deteriorated. Insuch a plasma display, an optical functional layer is sometimes providedto the optical sheet of the image source unit so as to improve thecontrast. The optical functional layer has light-transmissive portionsand light-absorbing portions and can adequately shield the externallight. The term “contrast” means the ratio between the brightness of thewhite portion showing maximum brightness (it is called “whitebrightness”) and the brightness of the black portion showing minimumbrightness (it is called “black brightness”) when displayingblack-and-white image.

Such an optical functional layer is disclosed in, for example, Patentdocument 1 (Japanese Patent Application Laid-open (JP-A) No.2006-189867) as an external light shielding layer which comprises: afilter base; and an external light shielding layer being formed on onesurface of the filter base, and comprising: a transparent resin-madebase, and wedge-shaped black stripes arranged parallel on one surface ofthe transparent resin-made base.

Patent document 2 (JP-A No. 02-097904) discloses a light-control filmwhich is a transparent film and comprises a first and a second mainsurfaces, wherein the first main surface has a plurality of grooves andthe grooves are filled with a light-absorbing material.

Patent document 3 (JP-A No. 2009-058658) discloses an optical sheetcomprising a light-transmissive layer having prism lines arrangedparallel, wherein each of the width of the prism lines is narrowertoward a top end and the intersectant portion of the upper face and theoblique face of the prism lines has roundness having a radius ofcurvature of 3-30 μm.

Patent document 4 (JP-A No. 2009-080198) discloses an optical sheetwhich is arranged at an observer side from an image light source andwhich comprises a plurality of layers controlling the light emitted fromthe image light source and transmitting the light to the observer side.In the optical sheet, at least one layer of the plurality of the layersis an optical functional layer comprising light-transmissive prismportions arranged parallel along the sheet face and light-absorbingportions arranged between the light-transmissive prism portions; and atleast one base of the light-absorbing portion in cross section in thesheet-thickness direction has a recess having a curved or polygonal lineso that the at least one side of the light-absorbing portion in crosssection in the sheet-thickness direction projects towards the sheetthickness direction.

Patent document 5 (JP-A No. 2008-046644) discloses a plasma displaydevice comprising: a plasma display panel; and a filter formed on theentire surface of the panel, wherein the filter comprises a base unit;and an external light shielding sheet including a plurality of patternunits formed on the base unit, wherein the bottom stage of the patternunit which is wider than the upper stage of the pattern unit is formedin a recessed shape.

SUMMARY OF THE INVENTION

The above-described optical functional layer can improve contrast of theimage display unit by absorbing light. However, a part of image lightwhich is desired not to be absorbed but to be emitted to the observerside even tends to be absorbed; so, the use efficiency of the imagelight tends to be deteriorated. In some cases, improving use efficiencyby improving the front brightness by converging the image light at thefront so as to reduce the power consumption as a whole, are desired.

In the filter for a display unit of Patent document 1, among imagelights incoming into the base made of a transparent resin material, animage light incoming at an angle larger than an angle formed by thenormal line of the sheet face is absorbed by the wedge-shaped blackstripes. Therefore, transmissivity of the image light lowers and therebyuse efficiency of the image light degreases, which are problematic.

The invention of Patent document 2 states that there is an effect toimprove transmissivity of the image light within the view angle range of±30° by using curved surface of the light-transmissive portion. However,the invention only has a feature regarding the shape oflight-transmissive portion; so, further improvement is required.

In the invention of Patent document 3, so as to improve moldability ofthermoplastic resin, roundness is given to the corners of the prismlines. However, by merely giving roundness of a certain curvature at thecorners of the prism lines, the expected optical effect cannot beobtained.

The invention of Patent document 4 obtains an effect of improving lighttransmissivity by forming recess portions in the light-absorbingportions. However, by only the modification of the structure, the effectof improving transmissivity of the image light is insufficient.

In addition, the invention of Patent document 5 does not consider theissue to improve transmissivity of the image light.

Accordingly, the present invention is to provide an image source unitwhich is capable of improving use efficiency of the image light. Theinvention also provides an image display unit comprising the imagesource unit.

Hereinafter, the present invention will be described. In order to makethe understanding of the present invention easier, reference numerals ofthe attached drawings are quoted in brackets; however, the presentinvention is not limited by the embodiment shown in the drawings.

The first aspect of the present invention is an image source unit (4)comprising: an image light source (5); and an optical sheet (10)laminated on the image light source, the optical sheet comprising: abase material layer (11); and an optical functional layer (12) formed onthe image light source side surface of the base material layer, theoptical functional layer comprising: light-transmissive portions (13)arranged parallel in a light transmissive manner along the sheet face;and light-absorbing portions (14) arranged in a light absorbing mannerbetween the light-transmissive portions, the image light source sideface of the light-transmissive portion having protrusions (17) eachhaving a curved or polygonal line so that the protrusions projecttowards the image light source side in cross section in thesheet-thickness direction.

The second aspect of the invention according to the first aspect of theinvention is characterized in that an adhesive layer (20) having arefractive index which is lower than that of the light-transmissiveportion is laminated on an image light source (5) side face of theoptical functional layer (12).

The third aspect of the invention according to the first or secondaspect of the invention is characterized in that the image light source(5) side face of the light-absorbing portion (14) has a recess portion(18) so that the bottom of the recess portion faces the opposite sidefrom the image light source and formed in curved or polygonal manner incross section in the sheet-thickness direction.

The fourth aspect of the invention according to the third aspect of theinvention is characterized in that the depth of the recess portion (18)of the light-absorbing portion (14) is in the range of 0.5-6.0 μm.

The fifth aspect of the invention according to any one of the first tofourth aspects of the invention is characterized in that the image lightsource (5) side of the light-absorbing portion (14) is covered with acovering layer.

The sixth aspect of the invention according to any one of the first tofifth aspects of the invention is characterized in that the elasticmodulus of the light-transmissive portion is 10 MPa or more and below2000 MPa.

The seventh aspect of the invention according to the second aspect ofthe invention is characterized in that the storage elastic modulus ofthe adhesive forming the adhesive layer (20) is 0.1 MPa or more andbelow 0.8 MPa.

The eighth aspect of the invention according to the seventh aspect ofthe invention is characterized in that the thickness of the adhesivelayer (20) is 20 μm or more and 50 μm or less.

The ninth aspect of the invention according to any one of the first toeighth asnects of the invention is characterized in that the opticalsheet (10) has an antireflection layer (23) or an anti-glare layerlocated on its surface opposite to the light source.

The 10th aspect of the invention according to anyone of the first toninth aspects of the invention further comprising a wavelength filterlayer (22) for controlling transmissivity of light having a certainwavelength.

The 11th aspect of the invention according to anyone of the first toninth aspects of the invention further comprising an electromagneticwave shielding layer (21) for shielding electromagnetic waves.

The 12th aspect of the present invention is an image display unit (1)comprising the image source unit (4) according to any one of claims 1 to11.

According to the invention, it is possible to efficiently use imagelight emitted from the image light source.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view showing a structure of an image display unit;

FIG. 2 is a cross-sectional view schematically showing a part of theimage source unit of the first embodiment of the present invention;

FIG. 3 is an enlarged plan of a part of the optical functional layer ofthe optical sheet provided to the image source unit shown in FIG. 2;

FIG. 4A is a plan showing an example of the light-absorbing portionhaving a triangle cross section;

FIG. 4B is a plan showing another example of the light-absorbing portionof which oblique line in cross section is a polygonal line;

FIG. 4C is a plan showing another example of the light-absorbing portionof which oblique line in cross section is a curved line;

FIG. 5 is a schematic view showing a part of process regarding anexample of producing method of the optical functional layer;

FIG. 6 is a schematic view showing a part of process regarding anotherexample of producing method of the optical functional layer;

FIG. 7 is a schematic view showing an example of optical path of animage light passing through the optical functional layer;

FIG. 8 is a schematic view showing a part of cross section of the imagesource unit according to the second embodiment;

FIG. 9 is an enlarged cross-sectional view showing a part of the opticalfunctional layer of the optical sheet provided to the image source unitshown in FIG. 8;

FIG. 10 is a schematic view showing examples of optical path of theimage light passing through the optical functional layer;

FIG. 11 is a schematic view showing a part of the cross section of theimage light unit according to another embodiment;

FIG. 12 is a schematic view showing examples of optical path of theimage light passing through the optical functional layer; and

FIG. 13 is a plan showing a tip (cutting chip) of diamond bite used forthe Example, seen from a rake face.

DESCRIPTION OF THE REFERENCE NUMERALS

-   10 optical sheet-   11 base material layer-   12 optical functional layer-   13 light-transmissive portion-   14 light-absorbing portion-   15 binder-   16 light-absorbing particle-   17 protrusion-   18 recess portion-   20 adhesive layer-   21 electromagnetic wave shielding layer-   22 wavelength filter layer-   23 antireflection layer

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The aforementioned functions and benefits of the present invention willbe apparent from the following modes for carrying out the invention.Hereinafter, the invention will be described based on the embodimentsshown in the drawings. However, the invention is not limited to theseembodiments.

FIG. 1 is an exploded perspective view schematically showing a plasmatelevision 1 as an image display unit which comprises an image sourceunit 4 according to a first embodiment of the invention. In FIG. 1, theupper right side of the drawing is the observer side and the lower leftside of the drawing is the back side of the plasma television. As seenfrom FIG. 1, the plasma television 1 comprises a plasma display panelunit 4 (PDP unit 4) as an image source unit 4 which is incorporated in ahousing formed by a front housing 2 and rear housing 3.

Other than the PDP unit 4, the plasma television 1 may comprise variousdevices conventionally provided to plasma televisions in its housing.Examples of the devices may be various electric circuits and coolingmeans.

FIG. 2 schematically shows a structure of the PDP unit 4. In FIG. 2, theright side of the drawing is the observer side. The PDP unit 4comprises: a display panel 5 (PDP 5) as an image light source; and anoptical sheet 10 disposed at the image light outgoing side of the PDP 5.In FIG. 2, for viewability, the repeating reference numerals andreference numerals of unexplained elements are partly omitted (same inthe following figures).

The POP 5 can be a conventional plasma display panel. Next, the opticalsheet 10 will be described.

The optical sheet 10 is a sheet shape member which is arranged at theobserver side from the image light source and which controls an incidentlight from the image light source side and transmits the light to theobserver side. The optical sheet 10 has a plurality of layers; as shownin FIG. 2, the optical sheet 10 at least comprises: a base materiallayer 11; and an optical functional layer 12 formed on the image lightsource side surface of the base material layer 11. In addition, theembodiment of the optical sheet 10 shown in FIG. 2 also comprises: anadhesive layer 20; an electromagnetic wave shielding layer 21; awavelength filter layer 22; and an antireflection layer 23. Hereinafter,each layer will be described.

The base material layer 11 is a layer to be the base for forming theoptical functional layer 12 as described below in detail. The basematerial layer 11 is preferably constituted by a material containingpolyethylene terephthalate (PET) as the main component. When the basematerial layer 11 contains PET as the main component, the base materiallayer 11 may contain other resins. In addition, various additives maybeadequately added thereto. Examples of conventional additives include:antioxidant such as phenol-based compounds and stabilizer such aslactone-based compounds. The term “main component” means that 50 mass %or more of PET is contained based on the whole material for forming thebase material (hereinafter, it means the same.).

The main component of the material constituting the base material layer11 is not necessarily PET; other materials can be used. Examples ofother materials include: polyester-based resin such as polybutyleneterephthalate, polyethylene naphthalate, terephthalic acid-isophthalicacid-ethylene glycol copolymer, and terephthalic acid-cyclohexanedimethanol-ethylene glycol copolymer; polyamide-based resin such asnylon 6; polyolefin-based resin such as polypropylene and polymethylpenten; acrylic resin such as polymethyl methacrylate; styrene-basedresin such as polystyrene and styrene-acrylonitrile copolymer;cellulose-based resin such as triacetylcellulose; imide-based resin; andpolycarbonate resin. To these resins, as required, additives such asultraviolet absorber, filler, plasticizer, and antistatic agent may beadequately added.

In this embodiment, in view of mass production, cost, and availabilityas well as its performance, a base material layer 11 is made of a resinmainly containing PET as a preferable mode of the invention.

The optical functional layer 12 is a layer for controlling optical pathof the image light incoming from the image light source side and foradequately absorbing stray light and external light. The opticalfunctional layer 12 has a cross section shown in FIG. 2 and extends fromthe front to the back of the drawing. FIG. 3 is an enlarged plan of oneof the light-absorbing portions 14 and the adjacent light-transmissiveportions 13 of the optical functional layer 12 in the optical sheet 10shown in FIG. 2. The optical functional layer 12 will be morespecifically described with reference to FIGS. 2, 3, and otheradequately indicated drawings.

The light-transmissive portions 13 has a function to transmit an imagelight and are arranged so that a shorter upper base and a longer lowerbase in the substantially trapezoid cross-section are arranged in adirection along the sheet plane of the optical sheet 10. When theoptical sheet 10 is arranged in the image display unit, the shorterupper base in the substantially trapezoid cross-section faces the imagelight source side. It should be noted that the cross-section of the faceof the shorter upper base of one light-transmissive portion 13 (i.e. theimage light source side) projects in a curved or polygonal manner; andthe light-transmissive portion 13 has a protrusion 17 at the image lightsource side. The term “projects in a curved or polygonal manner” means aline which is obtained by connecting both ends of the light-absorbingportion 14 of the image light source side face in the cross section (seebroken line in FIG. 3.) projects in a curved or polygonal manner towardthe image light source side. Thus, to be exact, the cross-sectionalshape of the light-transmissive portion 13 is not trapezoid.

The light-transmissive portions 13 have a refractive index N_(p) andsuch light-transmissive portions 13 can be made by curing a compositionfor constituting the below-described light-transmissive portion. Thevalue of refractive index N_(p) is not particularly limited; in view ofavailability of the material to be applied, 1.49-1.56 is preferable.

The composition for forming the light-transmissive portion ispreferably, for example, a light curable resin composition in which alight-curable prepolymer (P1), a reactive diluent monomer (M1), a moldrelease agent (S1), and a photopolymerization initiator (I1) are mixed.

Examples of the light-curable prepolymer (P1) include: prepolymer suchas epoxy acrylate-based, urethane acrylate-based, polyetheracrylate-based, polyester acrylate-based, and polythiol-basedprepolymer.

Examples of the reactive diluent monomer (M1) include: vinylpyrrolidone,2-ethylhexyl acrylate, β-hydroxy acrylate, and tetrahydrofurfurylacrylate.

Examples of the mold release agent (S1) include: a salt of phosphateester of tetradecanol ethylene oxide 10 mole-adduct/lauryl dimethylamine; a salt of phosphate ester of tetradecanol ethylene oxide 10mole-adduct/dimethyl stearyl amine; a salt of phosphate ester of laurylalcohol ethylene oxide 2 mole-adduct/ethylene oxide 10 mole-adduct oflauryl amine; a salt of phosphate ester of tetradecanol ethylene oxide 2mole-adduct/ethylene oxide 10 mole-adduct of stearyl amine; and a saltof phosphate ester of stearyl alcohol ethylene oxide 10mole-adduct/ethylene oxide 15 mole-adduct of stearyl amine.

Examples of the photopolymerization initiator (I1) include:hydroxybenzoyl compounds such as2-hydroxy-2-methyl-1-phenylpropane-1-one, 1-hydroxycyclohexyl phenylketone, and benzoin alkyl ether; benzoyl formate compounds such asmethyl benzoyl formate; thioxanthone compounds such as isopropylthioxanthone; benzophenones such as benzophenone; acylphosphine oxidecompounds such as 1,3,5-trimethylbenzoyl diphenylphosphine oxide,bis(2,4,6-trimethylbenzoyl)phenylphosphine oxide; and benzyl dimethylketal. Among them, the preferable ones in view of color protection ofthe light-transmissive portions 13, 13, . . . are2-hydroxy-2-methyl-1-phenylpropane-1-one, 1-hydroxycyclohexyl phenylketone, and bis(2,4,6-trimethyl benzoyl) phenylphosphine oxide. Itshould be noted that the amount of the photopolymerization initiator(I1) to be contained is preferably 0.5-5.0 mass % based on a total massof the composition for forming the light-transmissive portion (100 mass%).

The light-curable prepolymer (P1), the reactive diluent monomer (M1),the mold release agent (S1), and the photopolymerization initiator (I1)to be used may respectively be single species or a combination of two ormore species thereof.

As required, for property modification as well as improvement of coatingproperties and of mold releasability from the die roll when using dieroll in the production process, various additives such as silicone-basedadditive, rheology control agent, antifoaming agent, antistatic agent,and ultraviolet absorber can be added to the composition for forming thelight-transmissive portion.

Next, the light-absorbing portion 14 will be described. Thelight-absorbing portion 14 is arranged between the neighboringlight-transmissive portions 13; the light-absorbing portion 14 is anelement having a substantially trapezoid shape in cross section shown inFIGS. 1 and 2. The shorter upper base of the substantially trapezoid incross section is arranged at the longer lower base side of thelight-transmissive portion 13 and the longer lower base of thelight-absorbing portion 14 is arranged at the shorter upper base side ofthe light-transmissive portion. It should be noted that in the case ofthis embodiment, the face equivalent to the longer lower base of thesubstantially trapezoid cross section (i.e. the image light source sideface) has a recess formed in a curved or polygonal manner; and thelight-absorbing portion 14 has a recess portion 18 at the image lightsource side. The term “a recess portion” means an area recessed towardthe observer side (i.e. base material layer 11 side) to theabove-described broken line in FIG. 3. The depth of the recess portion18 is preferably 0.5 μm or more and 6.0 μm or less. When the depth ofthe recess portion 18 is less than 0.5 μm, the below-described effect todiffuse the image light may be reduced. On the other hand, when thedepth of the recess portion 18 exceeds 6.0 μm, in a case of applying anadhesive to the face having the recess portion 18 so as to laminateother layers, the adhesive tends not to follow the recess portion evenafter autoclave treatment; as a result, bubbles may be incorporated. Theoblique line of the substantially trapezoid cross section preferablyintersects with the normal to the plane of the optical sheet at an angleof 0° or more and 10° or less. When the angle of the oblique line isnearly 0′, the cross section of the light-absorbing portion 14 is nolonger substantially trapezoid, but rectangle.

Although the above description states that the cross-sectional shape ofthe light-absorbing portion is a substantially trapezoid shape havingtwo linear oblique lines, the present invention is not limited to theshape. Other examples of cross section of the light-absorbing portionare shown in FIGS. 4A, 4B, and 4C. FIG. 4A is a plan showing an exampleof the light-absorbing portion 14 a having a triangle cross section;FIG. 48 is a plan showing another example of the light-absorbing portion14 b of which oblique line in cross section is a polygonal line; andFIG. 4C is a plan showing another example of the light-absorbing portion14 c of which oblique line in cross section is a curved line;

In the case of FIG. 4A, the cross-sectional shape of the light-absorbingportion 14 a is substantially triangle. More specifically, the base ofthe substantially triangle is arranged between the shorter upper basesof the neighboring light-transmissive portions 13 a; the apex of thetriangle to the base is arranged at the base material layer side (i.elower side of the drawing). The oblique line of the substantiallytriangle intersects with the normal to the output plane of the opticalsheet at an angle of θ1. The angle θ1 is preferably in a range of morethan 0° and 10° or less; more preferably more than 0° and 6° or less.

In the case of FIG. 4B, an oblique line of the light-absorbing portion14 b (an oblique line of the light-transmissive portions 13 b, 13 b)consists of two lines, but not a single line. In other words, thecross-sectional shape has a polygonal oblique line. More specifically,the lower base side oblique line (i.e. upper side of FIG. 4B) makes anangle of θ2 with a normal to the output plane of the optical sheet. Theapex side oblique line (i.e. lower side of FIG. 4B) makes an angle of θ3with a normal to the output plane of the optical sheet. There is arelation: θ2>θ3. Both θ2 and θ3 are preferably within the range of morethan 0° and 10° or less, and more preferable angles are within the rangeof more than 0° and 6° or less. Although FIG. 4B shows an example of thelight-absorbing portion each of which oblique line consists of twooblique lines, the oblique line may be a polygonal line having more thantwo lines.

In the case of FIG. 4C, the oblique line of the light-absorbing portion14 c (i.e. also the oblique line of the light-transmissive portions 13c) is a curved line. In this way, the oblique line of the substantiallytrapezoid cross-sectional shape of the light-absorbing portion may be acurved line. Even in this case, the angle between the curved line andthe normal to the output plane of the optical sheet at theupper-base-side (lower side in FIG. 4C) is preferably smaller than theangle at the lower-base-side (upper side in FIG. 4C). In addition, everyangle on the curved line is preferably within the range of more than 0°and 10° or less, and more preferably within the range of more than 0°and 6° or less. The angle between the curved line and the normal to theoutput plane of the sheet is defined by an angle between the normal tothe output plane of the sheet and lines made by dividing a curved lineinto ten equal parts and connecting two adjacent ends of the segments.

The shape of the light-absorbing portion is not limited to the examples;it can be adequately modified as long as the shape is suitable forabsorbing the external light. For example, substantially rectanglecross-sectional shape may be possible. It should be noted that any shapeof the light-absorbing portion of the embodiment has a recess portion atthe image light source side of the optical functional layer in a curvedor polygonal manner.

The light-absorbing portions 14 are formed of a certain material havinga refractive index of N_(b) which is smaller than refractive index N_(p)of the light-transmissive portion 13. By setting the relation betweenthe refractive index N_(p) of the light-transmissive portions 13 and therefractive index N_(b) of the light-absorbing portions 14 asN_(p)>N_(b), it is possible to adequately reflect an image light emittedfrom the light source which enters into the light-transmissive portions13 based on Snell's law under certain conditions at an interface betweenlight-absorbing portions 14 and the light-transmissive portions 13. Thelight entering into the light-absorbing portion based on Snell's law isabsorbed. The difference between the refractive indexes N_(p) and N_(b)are not particularly limited; it is preferably more than 0 and 0.06 orless, more preferably more than 0 and 0.02 or less, furthermorepreferably more than 0.003 and 0.015 or less. When emphasizing the frontbrightness and view angle, the difference between the refractive indexesN_(p) and N_(b) is preferably large within the above-specified range;while, when lowering black brightness and emphasizing the contrast, thedifference between these refractive indexes is preferably small. Theterm “black brightness” means brightness of the black part which showsminimum brightness.

Although the relation: N_(p)>N_(b) is preferable in this embodiment, therelation between N_(p) and N_(b) is not limited to it. It is possible toform the light-absorbing portions 14 so that refractive index of thelight-transmissive portion and that of the light-absorbing portion arethe same or refractive index of the light-transmissive Portion issmaller than that of the light-absorbing portion.

In addition, the light-absorbing portion 14 of the embodiment is formedby filling the portion between the light-transmissive portions 13 with acomposition for constituting the light-absorbing portion, whichincludes: light-absorbing particles 16; and a binder 15. In other words,the light-absorbing particles 16 are dispersed in the binder 15. By thestructure, in the light-absorbing portion 14, the image light enteredinto the light-absorbing portion 14 can be absorbed at thelight-absorbing particles 16 without causing reflection based on Snell'slaw at the interface between the light-transmissive portion 13 and thelight-absorbing portion 14. Moreover, the light-absorbing particles 16can adequately absorb the external light incoming at a certain anglefrom the observer side, which results in improvement of the contrast.

In this case, the binder 15 is formed by a material having refractiveindex N_(b). The material to be used as the binder is not particularlylimited; for instance, a light curable resin composition in which alight curable prepolymer (P2), a reactive diluent monomer (M2), and aphotopolymerization initiator (I2) are mixed is preferably used.

Examples of light curable prepolymer (P2) include: urethane(meth)acrylate, polyester (meth)acrylate, epoxy (meth)acrylate, andbutadiene (meth)acrylate.

Examples of the reactive diluent monomer (M2) as monofunctional monomerinclude: vinyl monomers such as N-vinylpyrrolidone, N-vinylcaprolactone,vinylimidazole, vinylpyridine, and stylene; monomers of (meth)acrylicacid ester and (meth)acrylamide derivatives such as lauryl(meth)acrylate, stearyl (meth)acrylate, butoxyethyl (meth)acrylate,ethoxy diethylene glycol (meth)acrylate, methoxy triethylene glycol(meth)acrylate, methoxy polyethylene glycol (meth)acrylate, methoxydipropylene glycol (meth)acrylate, para-cumyl phenoxyethyl(meth)acrylate, nonylphenoxy polyethylene glycol (meth)acrylate,tetrahydrofurfuryl (meth)acrylate, isobornyl (meth)acrylate, cyclohexyl(meth)acrylate, benzyl methacrylate, N,N-dimethyl (meth) acrylamide,N,N-dimethylaminopropyl (meth)acrylate, and acryloylmorpholine. Examplesof the reactive diluent monomer (M2) as multifunctional monomer include:ethylene glycol di(meth)acrylate, diethylene glycol di(meth)acrylate,triethylene glycol di(meth)acrylate, polyethylene glycoldi(meth)acrylate, tripropylene glycol di(meth)acrylate,polytetramethylene glycol di(meth)acrylate, 1,4-butanedioldi(meth)acrylate, 1,6-hexanediol di(meth)acrylate, 1,9-nonanedioldi(meth)acrylate, 3-methyl-1,5-pentanediol di(meth)acrylate, neopentylglycol di(meth)acrylate, dimethyloltricyclodecane di(meth)acrylate,hydroxy pivalic acid neopentyl glycol di(meth)acrylate, bisphenol Apolypropoxydiol di(meth)acrylate, trimethylolpropane tri(meth)acrylate,ethoxylated trimethylolpropane tri(meth)acrylate, propoxylatedtrimethylolpropane tri(meth)acrylate, pentaerythritol tri(meth)acrylate,glyceryl tri(meth)acrylate, propoxylated glyceryl tri(meth)acrylate,tris(2-hydroxyethyl) isocyanurate triacrylate, pentaerythritoltetra(meth)acrylate, ditrimethylolpropane tetra(meth)acrylate,dipentaerythritol penta(meth)acrylate, and dipentaerythritolhexa(meth)acrylate.

Examples of the photopolymerization initiator (I2) include:1-hydroxycyclohexyl phenyl ketone,2-hydroxy-2-methyl-1-phenylpropane-1-one,2,2-dimethoxy-1,2-diphenylethane-1-one,2,4,6-trimethylbenzoyldiphenylphosphine oxide, andbis(2,4,6-trimethylbenzoyl) phenylphosphine oxide. Among them, thephotopolymerization initiator (I2) can be arbitrarily selected dependingon the irradiation apparatus for curing light curable resin compositionand curing property of the light curable resin composition. In thepresent invention, in view of curing property and cost of the lightcurable resin composition, the amount of photopolymerization initiator(I2) contained in the light curable resin composition based on a totalamount of the light curable resin composition (100 mass %) is preferably0.5-10.0 mass %.

The light curable prepolymer (P2), the reactive diluent monomer (M2),and the photopolymerization initiator (12) to be used may respectivelybe single species or a combination of two or more species thereof.

More specifically, the photopolymerizable component (specifically, thelight curable prepolymer and the reactive diluent monomer) consisting ofurethane acrylate, epoxy acrylate, tripropylene glycol diacrylate, andmethoxy triethylene glycol acrylate can be arbitrarily mixed in view ofrefractive index, viscosity, effect on the property of the opticalfunctional sheet layer 12, and so on.

Moreover, as required, additives such as silicone, antifoaming agent,leveling agent, and solvent may be added to the composition forconstituting the light-absorbing portion.

The light-absorbing particles 16 is included in the composition forconstituting the light-absorbing portion and acts as the stray light andexternal light absorber after the light-absorbing portion 14 is formed.

As the light-absorbing particles 16, light-absorbing colored particlessuch as carbon black are preferably used. However, the light-absorbingparticle 16 is not limited to it; colored particles which canselectively absorb a light having a certain wavelength can be used asthe light-absorbing particle 16 depending on the properties of the imagelight. More specifically, for example, colored glass beads or organicparticulates colored by carbon black, graphite, metal salt such as blackiron oxide, dye, and pigment, may be used. Particularly, in view ofcost, quality, and availability, the colored organic particulates arepreferably used. More specifically, for example, acrylic cross-linkedparticulate containing carbon black and urethane cross-linkedparticulate containing carbon black are preferably used. Such coloredparticles are usually contained in the composition for constituting thelight-absorbing portion within the range of 3-30 mass %. The averagediameter of the colored particles is preferably 1.0 μm or more and 20 μmor less. The term “the average diameter (of the particles)” means adiameter which can be obtained by particle size measurement inaccordance with mass distribution measurement. By using the coloredparticles having average diameter of 1.0 μm or more, it is possible toprevent the colored particles from not being strickled by a doctor bladeand thus remaining on the upper base of the light-transmissive portionswhen forming the light-absorbing portions 14, 14, . . . in accordancewith the below-described method.

The light absorbing means is not limited to the method by using thelight-absorbing particles of this embodiment. For example, the lightabsorbing means may be a method by coloring the entire composition forconstituting the light-absorbing portion by pigment or dye and formingan entirely-colored light-absorbing portion.

The light-absorbing portion 14 can be formed by using theabove-described composition for constituting the light-absorbing portionin accordance with the below-described method.

Next, the method for producing the optical functional layer 12 will bedescribed. FIG. 5 is a schematic view showing a part of process of anexample of producing method of the optical functional layer 12. FIG. 6is a schematic view showing a part of process of another example ofproducing method of the optical functional layer.

When producing the optical sheet 10, as shown in FIG. 5, alight-transmissive portion 13 is formed on a base material 11′ includingthe base material layer 11 to obtain a sheet 10′. To form thelight-transmissive portion 13, a die roll 42 having certain pitchgrooves corresponding to the shape of the light-transmissive portion 13is prepared. Then, the base material 11′ is fed between the die roll 42and a nip roll 41. The arrow V shown in FIG. 5 indicates the directionto feed the base material 11′. With feeding the base material 11′,droplet of the composition for constituting the light-transmissiveportion 30 is continuously supplied between the die roll 42 and the basematerial 11′ from a feeder 40. When supplying the composition forconstituting the light-transmissive portion 30 from the feeder 40 on thebase material 11′, a reservoir 31 of the composition for constitutingthe light-transmissive portion 30 should be formed between the die roll42 and the base material 11′. In the reservoir 31, the composition forconstituting the light-transmissive portion 30 spread on the basematerial 11′ along the width direction.

The composition for constituting the light-transmissive portion 30, thussupplied between the die roll 42 and the base material 11′, is filledbetween the base material 11′ and the die roll 42 by the pressure of thedie roll 42 and the nip roll 41. Thereafter, by irradiating light to thecomposition for constituting the light-transmissive portion by using alight irradiation unit 44 to cure the composition for constituting thelight-transmissive portion, the light-transmissive portion 13 can beformed. After forming the light-transmissive portion 13, the sheet 10′in which the light-transmissive portion 13 is formed on the sheet 11′ isseparated from the die roll 42 by being drawn through a mold-releasingnip roll 43.

Then, as shown in FIG. 6, the optical functional layer 12 is obtained byforming the light-absorbing portions 14 between the light-transmissiveportions 13 of the sheet 10′. More specifically, firstly, thecomposition for constituting the light-absorbing portion 36 is suppliedon the light-transmissive portion 13; then, by using a doctor blade 35,the composition for constituting the light-absorbing portion 36 isfilled in the grooves 37 between the light-transmissive portions 13.After that, the excessive amount of the composition for constituting thelight-absorbing portion 36 is strickled and the light is irradiated tothe composition for constituting the light-absorbing portion 36remaining in the grooves 37 between the light-transmissive portions 13to cure the composition. Accordingly, the light-absorbing portion 14 canbe formed. The arrow VI shown in FIG. 6 indicates the transferringdirection of sheet 10′.

At the phase, the elastic modulus of the light-transmissive portion 13is preferably 10 MPa or more and below 2000 MPa. If the elastic modulusof the light-transmissive portion 13 is 2000 MPa or more, thelight-transmissive portion is hardened and tends to cause crack andchip, the optical functional layer 12 shows poor appearance when formingthe light-absorbing portion 14 in the above-described method, andtransmissivity of the optical functional layer 12 tends to decrease. Thereason for the decrease of transmissivity is assumed that if thelight-transmissive portion 13 is too hard, when strickling the excessiveamount of the composition for constituting the light-absorbing portion36 supplied on the light-transmissive portion 13 by pressing the doctorblade 35 against the light-transmissive portion 13, it is hard to deformthe light-transmissive portion 13; thereby the excessive amount of thecomposition for constituting the light-absorbing portion 36 cannot befully strickled. By setting the elastic modulus of thelight-transmissive portion 13 within the above-specified range, whenpressing the doctor blade 35, the excessive amount of composition forconstituting the light-absorbing portion 36 can be fully strickledbecause the light-transmissive portion 13 deforms enough; thereby it ispossible to prevent causing of poor appearance of the optical functionallayer 12 and possible to prevent decreasing transmissivity of theoptical functional layer 12. If the elastic modulus of thelight-transmissive portion 13 is 10 MPa or less, the light-transmissiveportion 13 is too soft to separate from the die roll 42 in the processshown in FIG. 5.

In the above-described optical functional layer 12, the recess portionproduced in the light-absorbing portion is formed by a binder monolayer;however, in view of adjusting the depth of the recess portion, acovering layer may be formed on the binder by laminating thecomposition. The refractive index of the covering layer can also beadequately adjusted. For example, if the refractive index of thecovering layer is set to the same value as that of the adhesive layer,light refracts at an interface between the covering layer and thebinder. If the refractive index of the covering layer is set to the samevalue as that of the binder, light refracts at an interface between theadhesive layer and the binder layer. By using the covering layer, thedepth of the recess position produced in the light-absorbing portion canbe adjusted. As the result, it is possible to adjust refraction of lightand possible to produce the optical sheet easily.

The adhesive layer 20 will be described with reference to FIG. 2. Theadhesive layer 20 is a layer made of an adhesive composition containingan adhesive. As the adhesive, a conventional one which exhibits requiredoptical transparency, adherence, and weatherability can be used. Theadhesive composition may contain, for instance, ultraviolet absorber,near-infrared absorber, neon absorber, and toning color.

The term “adhesive” means a kind of adhesive agent that is adherablewith the adherence of its surface by only an adequate pressure (usuallyat a degree lightly pressed by hand). To attain the adherence of theadhesive, usually, physical energy and actions such as heating,humidification, delivery of radiation (e.g. ultraviolet ray, electronbeam) is not particularly required; chemical reaction such aspolymerization reaction is not required either. Moreover, the adhesiveis the one which can maintain the removable low-tack adhesive force overtime after the adhesion.

The thickness of the adhesive layer 20 is preferably 20 μm or more and50 μm or less. The thickness of the adhesive layer 20 means thethickness of the thickest part of the adhesive layer 20. If the adhesivelayer 20 is thinner than 20 μm, the following capability to the recessand the protrusion declines, which causes problems of bubble inclusion;if the adhesive layer 20 is thicker than 50 μm, it is difficult touniformly adhere the adhesive composition.

In addition, the storage elastic modulus of the adhesive of the adhesivelayer 20 is preferably 0.1 MPa or more and 0.8 MPa or less. If thestorage elastic modulus is more than 0.8 MPa, the following capabilityto the recess and protrusion declines, which causes problems of bubbleinclusion; if the storage elastic modulus is less than 0.1 MPa, theadhesive composition is so soft that it may protrude outside thelaminated layers resulting in the formation of the fouling, which maycause inconvenience.

In view of enhancing adhesiveness to both the below-describedelectromagnetic wave shielding layer 21 and the above-described opticalfunctional layer 12, the adhesive layer 20 preferably comprises anadhesive having acid number. Examples of adhesive having acid numberinclude: natural rubber or synthetic resin having acid number, and onecomprising substance of which molecule has carboxyl group(s). Morespecifically, in view of high transparency, the adhesive having acidnumber is preferably an acrylic adhesive. Moreover, in view of improvingadhesiveness to both the electromagnetic wave shielding layer 21 and theoptical functional layer 12, the acid number of the acrylic adhesive ispreferably one or more.

As the acrylic adhesive having acid number included in the adhesivelayer 20, an adhesive, which exhibits adequate adhesive force,transparency, and applicability and which does not substantially changethe transmission spectrum of the optical sheet of the present invention,is properly selected among the conventionally used adhesives.

The acrylic adhesive having acid number is produced by polymerizationincluding at least an alkyl (meth) alkyl acrylate ester monomer; it isgenerally a copolymer of an alkyl (meth) alkyl acrylate ester monomerhaving about C₁-C₁₈ alkyl group and a monomer having carboxyl group. Theadhesive performance of the adhesive contained in the adhesive layer 20can be attained in a manner that carboxyl group existing in the adhesivemolecule strongly adsorbs the surface of a copper mesh layer of theelectromagnetic wave shielding layer 21.

Examples of the alkyl (meth)acrylate ester monomer include: methyl(meth)acrylate, ethyl (meth)acrylate, n-propyl (meth)acrylate,sec-propyl (meth)acrylate, n-butyl (meth)acrylate, sec-butyl(meth)acrylate, tert-butyl (meth)acrylate, isoamyl (meth)acrylate,n-hexyl (meth)acrylate, cyclohexyl (meth)acrylate, n-octyl(meth)acrylate, isooctyl (meth)acrylate, 2-ethylhexyl (meth)acrylate,undecyl (meth)acrylate, and lauryl (meth)acrylate. Among them, butylacrylate and 2-ethylhexyl acrylate are preferable; a combination ofbutyl acrylate and 2-ethylhexyl acrylate is preferably used.

The alkyl (meth)acrylate ester is usually copolymerized in the acrylicadhesive at a ratio of 30.0-99.5 parts by mass.

Moreover, examples of the monomer having carboxyl group for forming theacrylic adhesive may include: a monomer containing carboxyl group suchas (meth)acrylic acid, itaconic acid, crotonic acid, maleic acid,monobutyl maleate, and β-carboxyethyl acrylate.

Further, as the acrylic adhesive, other than the above examples,monomers containing other functional groups may be copolymerized withinthe range which does not undermine the property of the acrylic adhesive.Examples of the monomer having other functional groups include:hydroxyl-group-containing monomers such as 2-hydroxyethyl(meth)acrylate, 2-hydroxypropyl (meth)acrylate, and allyl alcohol;amide-group-containing monomers such as (meth)acrylamide, N-methyl(meth)acrylamide, and N-ethyl (meth)acrylamide; monomers containing bothamide group and methylol group such as N-methylol(meth)acrylamide anddimethylol (meth) acrylamide; amino-group-containing monomers such asaminomethyl (meth)acrylate and dimethyl aminoethyl (meth)acrylate; andepoxy-group-containing monomers such as allyl glycidyl ether and(meth)acrylic acid glycidyl ether. In addition, not onlyfluorine-substituted (meth)alkyl acrylate ester and (meth)acrylonitrile, but also vinyl-group-containing aromatic compounds suchas styrene, methylstyrene, vinyl pyridine, and vinyl acetate as well ashalogenated vinyl compounds can be exemplified.

Still further, as the acrylic adhesive, other than the above-describedmonomers having other functional groups, other monomers havingethylene-based double bond can be used. Examples of monomer havingethylene-based double bond include: diester of α, β-unsaturated dibasicacid such as dibutyl maleate, dioctyl maleate, and dibutyl fumarate;vinyl ester such as vinyl propionate; vinyl ether; and vinyl aromaticcompound such as vinyl toluene.

Together with the monomers having ethylene-based double bond, a compoundhaving two or more ethylene-based double bond can be used. Examples ofsuch compounds include: divinylbenzene, diallyl maleate, diallylphthalate, ethylene glycol di(meth)acrylate, trimethylolpropanetri(meth)acrylate, and methylene bis(meth)acrylamide.

Still further, other than the above monomers, monomers havingalkoxyalkyl chain can be used. Examples of alkoxyalkyl (meth)acrylateester include: 2-emthoxyethyl (meth)acrylate, methoxyethyl(meth)acrylate, 2-methoxypropyl (meth)acrylate, 3-methoxypropyl(meth)acrylate, 2-methoxybutyl (meth)acrylate, 4-methoxybutyl(meth)acrylate, 2-ethoxyethyl (meth)acrylate, 3-ethoxypropyl(meth)acrylate, and 4-ethoxybutyl (meth)acrylate.

As the commercially available acrylic adhesives, for example, acommodity name “5407” manufactured by The Nippon Synthetic ChemicalIndustry Co., Ltd. is suitably used.

The adhesive layer 20 may contain an antioxidant. By using the adhesivelayer containing an antioxidant, it is possible to prevent discolorationof the electromagnetic wave shielding layer 21 while using the adhesivehaving acid number for attaining favorable adhesiveness. The compoundsto be used as the antioxidant may be selected from the group consistingof: benzotriazole-based antioxidant, phenol-based antioxidant,phosphite-based antioxidant, amine-based antioxidant, andsulfur-containing organic metal salt-based antioxidant. Among them, inview of preventing discoloration of the copper mesh layer of theelectromagnetic wave shielding layer 21 into blue, the antioxidantcontained in the adhesive layer 20 is preferably benzotriazole-basedantioxidant.

Examples of the benzotriazole-based antioxidant may be a compoundcharacterized by including at least the structure of the followingFormula (1) as the skeleton, as well as the sodium salt, calcium salt,and amine salt thereof. Examples of substituents which may be includedin the formula (1) include: an alkyl group which may includesubstituent(s), an aryl group which may include substituent(s), and ahalogen atom.

More specific examples include: 1,2,3-benzotriazoie (i.e.1H-benzotriazole), 1H-benzotriazole sodium salt,4-methyl-1H-benzotriazole, 5-methyl-1H-benzotriazole,4-methyl-1H-benzotriazole potassium salt, 5-methyl-1H-benzotriazolepotassium salt, 4-methyl-1H-benzotriazole amine salt,5-methyl-1H-benzotriazole amine salt,2-(3,5-di-t-butyl-2-hydroxyphenyl)-5-chlorobenzotriazole, and2-(3,5-di-t-amyl-2-hydroxyphenyl)benzotriazole. Among them,1,2,3-benzotriazole (i.e. 1H-benzotriazole) is preferable.

In the adhesive layer 20, to obtain sufficient adhesive force of theadhesive layer 20 and not to cause surface discoloration of the coppermesh layer of the electromagnetic wave shielding layer 21, one or moreparts by mass of the above benzotriazole-based antioxidant may bepreferably contained based on 100 parts by mass of the above adhesive.If the content of the antioxidant is below the above-described range,even when the antioxidant is contained in the adhesive layer 20,discoloration of the copper mesh layer of the electromagnetic waveshielding layer 21 may not be sufficiently prevented.

It is more preferable that the adhesive layer 20 contains an adhesive ofwhich acid number is 1 or more and 1 or more parts by mass of thebenzotriazole-based antioxidant based on 100 parts by mass of theadhesive.

In addition, as required, curing agent (crosslinking agent) based one.g. isocyanate compounds, tackifier, silane coupling agent, and fillermay be added to the adhesive layer.

The electromagnetic wave shielding layer 21 will be described withreference to FIG. 2. As the name indicates the function, theelectromagnetic wave shielding layer 21 is a layer which can shieldelectromagnetic wave. As long as the layer has the function, theelectromagnetic wave shielding means is not particularly limited. Theelectromagnetic wave shielding layer maybe the copper mesh layer formedon a transparent base material by etching, printing, vapor deposition,or sputtering; the electromagnetic wave shielding layer is adequatelydesigned depending on the type of electromagnetic wave to be shield.when the method, in which the mesh is formed by photolithography processof a metal foil after laminating the transparent base material and themetal foil with an adhesive, is selected as the method of forming thecopper mesh layer (for example, Japanese Patent Application Laid-openNo. 11-145678), it is possible to prevent discoloration of theelectromagnetic wave shielding layer 21 by adding the above antioxidanteven to the adhesive.

Next, the wavelength filter layer 22 will be described. The wavelengthfilter layer 22 is a layer for controlling transmission of light havinga certain wavelength. As required, the wavelength of the light to becontrolled can be properly selected. Specific examples of the layer maybe: a layer which cuts neon line emitted from PDP or cuts infrared ray,near-infrared light, and ultraviolet ray; and a tone-adjusting layer.Hereinafter, a near-infrared light shielding layer (near-infrared lightabsorbing filter), a neon line shielding layer (neon line absorbingfilter), a tone adjusting layer (tone adjusting filter), and aultraviolet shielding layer (ultraviolet absorbing filter) will bedescribed.

Examples of the near-infrared light absorbing filter include: acommercially available film containing a near-infrared light absorbent(e.g. commodity name “2832” manufactured by Toyobo Co., Ltd.); a filmobtained by film forming of a composition of which adhesive layer orresin layer contains a near-infrared light absorbing pigment; and a filmobtained by applying the above composition to a transparent basematerial or other functional filter and then, as required, for example,by drying and hardening the composition.

Examples of near-infrared light-absorbing pigment may be the one whichabsorbs light having a wavelength range of near-infrared light regiongenerated by discharge of xenon gas emitted by PDF', namely, thewavelength range of 800-1100 nm. The transmissivity of the near-infraredlight in the band is preferably 20% or less, more preferably 10% orless. At the same time, the near-infrared light absorbing filterpreferably exhibits sufficient transmissivity in the visible lightrange, i.e. in the wavelength range of 380-780 nm.

Specific examples of the near-infrared light absorbing pigment include:organic-based near-infrared light absorbing Pigments of, such as,polymethine-based compound, cyanine-based compound, phthalocyanine-basedcompound, naphthalocyanine-based compound, naphthoquinone-basedcompound, anthraquinone-based compound, dithol-based compound,immonium-based compound, diimmonium-based compound, aminium-basedcompound, pyrylium-based compound, cerylium-based compound,squarylium-based compound, copper complexes, nickel complexes, anddithol-based metal complexes; and inorganic-based near-infrared rayabsorbing pigments of, such as, tungsten oxide, tin oxide, indium oxide,magnesium oxide, titanium oxide, chromium oxide, zirconium oxide, nickeloxide, aluminum oxide, zinc oxide, iron oxide, ammonium oxide, leadoxide, bismuth oxide, and lanthanum oxide. These may be used alone orused in combination of two or more thereof.

Examples of binder resin for dispersing the near-infrared ray absorbingpigment may be a resin such as polyester resin, polyurethane resin,acrylic resin, and epoxy resin. Examples of drying and curing method ofthe binder resin may be: a drying-solidifying method by evaporatingsolvent (or dispersion media) from the solution (or emulsion); a curingmethod employing polymerization and/or cross-linking reaction by energysuch as heat, ultraviolet rays, and electron beam; or other curingmethods employing polymerization and/or cross-linking reaction offunctional group in the resin (e.g. hydroxyl group and epoxy group)with, for example, an isocyanate group in the curing agent.

The neon line absorbing filter is provided so as to absorb neon light(namely, emission spectrum of neon atom) radiated from the PDP when theoptical filter is used for the plasma display. The emission spectalrange of neon light is in a wavelength range of 550-640 nm, so the neonline absorbing filter is preferably designed so that the spectraltransmissivity is 50% or less in the wavelength of 550-640 nm. The neonabsorbing filter may be: a membrane made of a composition in which aconventionally used dye having an absorption maximum in a wavelengthrange of at least 550-640 nm is dispersed in a binder resin exemplifiedin the description of the near-infrared light absorbing filter; or afilm obtained by applying the composition on a transparent base materialor other functional filter and then, as required, for example, by dryingand curing the applied composition. Specific examples of the neon lineabsorbing dye include: cyanine-based, oxonol-based, methine-based,subphthalocyanine-based, and porphyrin-based compounds. The binder resinmay be the one exemplified in the description about the near-infraredray absorbing dye.

The filter for adjusting color tone is the one to adjust color of thefilter for display so as to improve purity and color reproduction rangeof the light emitted from the panel as well as to improve color ofdisplay in the off state. Examples of the color-tone adjusting filtermay be: a membrane made of a composition in which a color-tone adjustingdye is dispersed in a resin; or a film obtained by applying thecomposition on a transparent base material or other functional filterand then, as required, for example, by drying and curing the appliedcomposition. As the color-tone adjusting dye, among known dyes eachhaving wavelength of maximum absorption in a visible light range of380-780 nm, the dyes can be used in arbitrary combination depending onthe intended purpose. Examples of the known dye usable as the color-toneadjusting dye include: dyes disclosed in Japanese Patent ApplicationLaid-Open (JP-A) No. 2000-275432, JP-A No. 2001-188121, JP-A No.2001-350013, and JP-A No. 2002-131530. In addition, dyes (which absorbvisible light such as yellow light, red light and blue light) such asanthraquinone-based, naphthalene-based, azo-based, phthalocyanine-based,pyrromethene-based, tetraazaporphyrin-based, squarylium-based, andcyanine-based dyes can be used as the color-tone adjusting dye. Thebinder resin may be the one exemplified in the description of theabove-described near-infrared light absorbing filter.

Examples of ultraviolet absorbing filter may be: a membrane made of acomposition in which a ultraviolet absorber is dispersed in a binderresin; or a film obtained by applying the composition on a transparentbase material or other functional filter and then, as required, forexample, by drying and curing the applied composition. Examples of theultraviolet absorber include: an organic compound such as benzotriazoleand benzophenone; and an inorganic compound such as microparticulatedzinc oxide and cerium oxide. The binder resin may be the one exemplifiedin the description of the above-described near-infrared light absorbingfilter.

Next, the antireflection layer 23 will be described. The antireflectionlayer 23 is disposed at the most observer side of the optical sheet anda layer having a function for preventing reflection of the externallight. By the antireflection layer 23, it is possible to inhibit thereflection of the external light at the surface of the observer side ofthe optical sheet and to inhibit the returning of the reflected light tothe observer side, that is to say, it is possible to reduce thereflected glare. Such an antireflection layer 23 can be formed, forexample, by using a commercially available antireflection film.

As above, the base material layer 11, the optical functional layer 12,the adhesive layer 20, the electromagnetic wave shielding layer 21, thewavelength filter layer 22, and the antireflection layer 23 have beendescribed based on the embodiment. However, the present invention can beformed by including at least the base material layer 11 and the opticalfunctional layer 12; depending on the intended purpose, layers otherthan the above-described layers having various functions can beprovided. More specifically, the invention can be formed by adhering,for example, an anti-glare layer and a hard coating layer with anadhesive layer to the unit including the base material layer 11 and theoptical functional layer 12. If the adhesive consists ultravioletabsorber, near-infrared light absorber, neon line absorber, toningcolor, and so on, the adhesive layer can be used also as a wavelengthfilter layer. Order for laminating these layers and the number of thelayers are properly determined depending on the intended purpose of theoptical sheet. Hereinafter, the anti-glare layer and the hard coatinglayer will be described.

The anti-glare layer is a layer to inhibit glare; it is also called AGlayer. As the anti-glare layer, commercially available one can be used.

The hard coating layer is also called HC layer. The hard coating layeris a layer made of a film which exhibits abrasion-resistant to protectthe image display face from scratching.

In the plasma television 1, the layer structure of the optical sheet 10may be modified and the adhesive layer 20 may be directly adhered to thePDP 5. As the adhesive layer 20 is disposed, even when the optical sheet10 is directly adhered to the PDP 5, the protrusion 17 will not bedeformed.

Hereinafter, the optical path of the image light passing through theoptical functional layer 12 in the image display unit 1 will bedescribed. As described above, the optical functional layer 12comprises: the light-transmissive portions 13 respectively having theprotrusion 17 at the image light source 5 side thereof; and thelight-absorbing portions 14 respectively having the recess portion 18 atthe image light source 5 side thereof. By the optical functional layer12 having the above structure, the image source unit 4 and the imagedisplay unit 1 using the image source unit 4 can improve use efficiencyof the image light.

The mechanism how the optical sheet 10 can improve use efficiency of theimage light will be described with reference to FIG. 8. FIG. 7 is aschematic view showing examples of optical path of an image lightpassing through the optical functional layer 12. It should be notedthat, to help understanding of the optical path, FIG. 7 and thebelow-indicated drawings which describe the optical path exaggerate therefracting angle.

As shown in FIG. 7, the image light L1 incoming into thelight-transmissive portion 13 at a certain angle firstly enters theprotrusion 17 and is refracted. The obliquity angle θa of the imagelight L1 entered from the protrusion 17 into the light-transmissiveportion 13 with respect to the normal line of the sheet face isrelatively smaller than when the protrusion 17 is not provided, namely,when the upper base and the lower base of the light-transmissive portionare formed parallel. Hence, the image light which enters the protrusion17 is refracted in a converging direction. Apart of the image lightentered into the light-transmissive portion 13 is absorbed by enteringinto the light-absorbing portion from the oblique line of thelight-absorbing portion 14; however, as described above, by refractingthe image light entered into the light-transmissive portion 13 to theconverging direction, it is possible to reduce the image light beingabsorbed in the light-absorbing portion 14. In other words, byconverging the image light at the protrusion 17, a part of the imagelight which hits the oblique line of the light-absorbing portion 14 whenthe protrusion 17 is not provided does not hit the oblique line of thelight-absorbing portion 14 anymore. In addition, image light having atotal-reflection angle when it hits the oblique line of thelight-absorbing portion 14 increases; such image light will not beabsorbed at the light-absorbing portion 14. In this way, the imagelight, which is not absorbed at the light-absorbing portion 14 anymore,is outputted from the base material layer 11 side face of the opticalfunctional layer 12 to the observer side.

On the other hand, the image light L2 incoming into the light-absorbingportion 14 at a certain angle firstly enters from the recess portion 18into the light-absorbing portion 14 and is refracted. The obliquityangle θb of the image light L2 entered from the recess portion 18 intothe light-absorbing portion 14 with respect to the normal line of thesheet face is relatively larger than when the recess portion 18 is notprovided, namely, when the base of the light-absorbing portion is formedin parallel with the face of the base material layer 11. Hence, theimage light entered from the recess portion 18 into the light-absorbingportion 14 is refracted in the diffusion direction. A part of the imagelight entered into the light-absorbing portion 14 is absorbed at thelight-absorbing particles 16 of the light-absorbing portion 14; however,as described above, by refracting the image light entered into thelight-absorbing portion 14 to the diffusion direction, it is possible totransmit the image light from the oblique line of the light-absorbingportion 14 to the light-transmissive portion 13 and possible to reducethe image light to be absorbed in the light-absorbing portion 14. Inother words, by the image light is diffused at the recess portion 18, apart of the image light, which has been absorbed at the light-absorbingportion 14 in a case where the recess portion 18 is not provided, is notabsorbed at the light-absorbing portion 14 but outputted from the basematerial layer 11 side of the optical functional layer 12 to theobserver side through the light-transmissive portion 13.

As seen above, according to the optical functional layer 12, by thelight-transmissive portion 13 having the protrusion 17, it is possibleto reduce the image light absorbed at the light-absorbing portion 14,thereby it is possible to improve use efficiency of the image light.Moreover, by the light-absorbing portion 14 having the recess portion18, it is possible to further reduce the image light absorbed at thelight-absorbing portion 14, thereby the use efficiency of the imagelight can be improved.

In view of converging the image light more at the protrusion 17, therefractive index N_(p) of the light-transmissive portion 13 ispreferably higher than the refractive index N_(n) of the adhesive layer20; and the difference between the refractive index N_(g) and therefractive index N_(n) is preferably larger than 0.05. In addition, inview of diffusing the image light more at the recess portion 18, therefractive index N_(b) of the light-absorbing portion 14 is preferablyhigher than the refractive index N_(n) of the adhesive layer 20; thedifference between the refractive index N_(b) and the refractive indexN_(n) is preferably larger than 0.05.

Further, as above, according to the optical functional layer 12, sinceuse efficiency of the image light can be improved in the direction ofview angle expansion, by deepening the light-absorbing portion 14 (i.e.by thickening in the thickness direction of the optical functional layer12) in response to the degree of the view angle expansion, it ispossible to improve contrast while maintaining the view angle. Stillfurther, when using total reflection (caused by the refractive indexdifference between the light-transmissive portion 13 and thelight-absorbing portion 14) at the interface between thelight-transmissive portion 13 and the light-absorbing portion 14, sincethe fully-reflected light is diffused by the protrusion 17 of thelight-transmissive portion 13, it is possible to improve view angleproperty and color unevenness caused by wavelength dispersion of thetotal reflection.

Accordingly, the image source unit and the image display unit using theimage source unit of the embodiment can improve use efficiency of theimage light.

FIG. 8 is a schematic view showing a cross section of the image sourceunit 54 of the second embodiment and the layer structure. The imagesource unit 54 comprises: a plasma display panel 5 (POP 5) as an imagelight source 5; and an optical sheet 60. The optical sheet 60 is asheet-type member to control the light incoming from the image lightsource 5 side and output the light to the observer side and is disposedat the image outgoing side of the image light source 5.

Plasma display panel may be a conventional one.

The optical sheet 60 has a plurality of layers; as shown in FIG. 8, itat least comprises: the base material layer 11; and an opticalfunctional layer 62 formed on the image light source 5 side face of thebase material layer 11. The optical sheet 60 shown in FIG. 8 alsocomprises an adhesive layer 70, the electromagnetic wave shielding layer21, the wavelength filter layer 22, and the antireflection layer 23.

In the optical sheet 60, the base material layer 11, the electromagneticwave shielding layer 21, the wavelength filter layer 22, and theantireflection layer 23 are in common with those of the optical sheet10, so the descriptions are omitted. In addition, in the optical sheet60, in the same manner as the optical sheet 10, other functional layerscan be laminated.

As shown in FIG. 8, the optical functional layer 62 comprises: alight-transmissive portion 63 of which cross sectional shape issubstantially trapezoid in a cross section perpendicular to the outputface of the optical sheet 60; and the light-absorbing portions 64arranged between the light-transmissive portions 63. FIG. 9 is anenlarged cross-sectional view of the optical sheet in which threelight-absorbing portions 64 and the adjacent light-transmissive portions63 are shown. The optical functional layer 62 will be described withreference to FIGS. 8 and 9 as well as adequately indicated drawings.

In the light-transmissive portion 63, the shorter upper base side andthe longer lower base side of the substantially trapezoid are arrangedalong the sheet face of the optical sheet 60. Here, as seen from FIGS. 8and 9, the shorter upper base side of the light-transmissive portion 63is formed so that the protrusion seen from the light-transmissiveportion 63 is the convex lens portion 67. So, the convex lens portion 67in this cross section is swelling toward the image light source sidewith respect to a line obtained by connecting ends of the image lightsource side face of the two adjacent light-absorbing portions 64 (seethe broken line IX-IX in FIG. 9.). Therefore, by the refractive indexdifference from that of the adjacent adhesive layer 70 and the effect ofthe lens shape, it is possible to converge the optical path of the imagelight in the direction closer to the direction normal to the front face.The difference of the refractive index between the convex lens portion67 and the adhesive layer 70, and the optical path will be describedlater.

The shape of the convex lens portion 67 is not particularly limited aslong as the convex lens portion can converge the optical path of theimage light into a direction closer to the direction normal to the frontface in the above-described manner. Examples of the shape include thespherical and the nonspherical shape. The pitch of the convex lensportion 67 is preferably 30-100 μm.

Other elements of the light-transmissive portion 63 are in common withthose of the light-transmissive portion 13 of the optical sheet 10; sothe descriptions is omitted.

The light-absorbing portion 64 is formed by filling a binder 65, inwhich light-absorbing particles 66 are dispersed, between thelight-transmissive portions 63. The light-absorbing portion 64 in thisembodiment is different from the light-absorbing portion 14 from thepoint that the light-absorbing portion 64 does not have the recessportion. Other elements are in common with those of the light-absorbingportion 14, so the descriptions will be omitted.

Next, the adhesive layer 70 will be described. The adhesive layer 70, inthe optical functional layer 62, is laminated on the face where theconvex lens portion 67 is formed for the purpose of adhering the opticalfunctional layer 62 to another member.

The refractive index of the adhesive layer 70 is a refractive indexN_(n) which is at least lower than a refractive index N_(p) of thelight-transmissive portion 63. By setting refractive index N_(n) so, asdescribed below, the convex lens portion 67 can control the optical pathof the image light toward the front side direction adequately. That is,the convex lens portion 67 projects toward the image light source 5side; and the refractive index at the observer side of the interfacebetween the convex lens portion 67 and the adhesive layer 70 is set tobe higher than the refractive index at the image light source side ofthe interface.

Other elements of the adhesive layer 70 are in common with those of theadhesive layer 20 of the above-described optical sheet 10; so, thedescriptions will be omitted.

Such an image source unit 54 can be used for the image display unit.Hereinafter, the mechanism how the front brightness can be improved byusing the image display unit comprising the image source unit 54 will bedescribed with reference to the examples of optical path of, forexample, the image light. The examples of the optical path are shown inFIG. 10.

The image light L3 is a light emitted parallel with the normal directionof the sheet from the image light source (PDP) 5 and passes through theapex of the convex lens portion 57; therefore, the light is transmittedto the front face without being refracted.

The image light L4 is an image light which enters into thelight-transmissive portion 63 at a slight angle to the normal directionof the sheet. The image light L4 is corrected to travel parallel withsubstantially the normal direction of the sheet and transmitted to thefront face by the effect of the convex lens portion 67.

The image light L5 is an image light which enters into thelight-transmissive portion 63 at a considerable angle with respect tothe normal direction of the sheet. By the effect of the convex lensportion 67, even such image light L5 can be refracted at a closer angleto the normal direction of the sheet, which results in the improvementof the front brightness.

The image light L6 is an image light which enters into thelight-transmissive portion 63 at a considerable angle with respect tothe normal direction of the sheet in the same manner as the traveling ofthe image light L5. The image light L6 is the image light which iscertainly absorbed by the light-absorbing portion 64 if the convex lensportion 67 is not provided. However, by the effect of the convex lensportion 67, the image light L6 can be refracted at an angle closer tothe normal direction of the sheet and the refracted light can bereflected at the interface between the light-absorbing portion 64 andthe light-transmissive portion 63; and the refracted image light L6 isoutputted.

The external light L7, on the other hand, enters into thelight-absorbing portion 64 and is absorbed by the light-absorbingparticle 66. Accordingly, the contrast can be improved.

As seen above, the image source unit 54 can be provided with a layerstructure suitable for applying the image display unit such as plasmatelevision and can improve the front brightness and the use efficiencyof the image light.

FIG. 11 is a schematic view showing a layer structure of the image lightunit 104 in cross section, according to another embodiment. The imagesource unit 104 comprises: the plasma display panel 5 (PDP 5) as animage light source 5; and an optical sheet 110. The optical sheet 110 isa sheet-type member which is arranged at the image output side of theimage light source 5 and outputs the light entered from the image lightsource 5 side to the observer side.

A plasma display panel 5 may be a conventional one.

The optical sheet 110 comprises: the antireflection layer 23, theoptical functional layer 112, the high-refractive index layer 119, thebase material layer 11, and the adhesive layer 70; and these layers arelaminated. In the embodiment, each of the above layers has a crosssectional shape shown in FIG. 11 and extends from the front to the backof the drawing. The base material layer 11 and the antireflection layer23 are in common with those of the optical sheet 60, so the descriptionwill be omitted. Moreover, the adhesive layer 70 may be the one whichcan adhere the optical sheet 110 to the PDP 5; it is made of aconventional adhesive.

Hereinafter, the optical functional layer 112 and the high-refractiveindex layer 119 will be described.

The optical functional layer 112, as shown in FIG. 11, comprises:light-transmissive portions 113 having substantially trapezoid shape incross section perpendicular to the output face of the optical sheet 110;and a light-absorbing portion 114 arranged between thelight-transmissive portions 113.

In the light-transmissive portion 113, the shorter upper base side andthe longer lower base side of the substantially trapezoid crosssectional shape are arranged along the sheet face of the optical sheet110. The upper base side of the light-transmissive portion 113, as seenfrom FIG. 13, is formed in a manner to be a concave lens portion 117seen from the light-transmissive portion 113. Hence, the face equivalentto the shorter upper base (i.e. the observer side face) of thesubstantially trapezoid cross sectional shape of the embodiment hasrecesses of which bottom faces toward the base material layer 11 sidewith respect to the broken line XI-XI in FIG. 11. Accordingly, by thedifference of the refractive index between the light-transmissiveportion 113 and the adjacent high-refractive index layer 119 and effectof the lens shape, it is possible to converge the optical path of theimage light emitted from the image light source in the direction closerto the direction normal to the front face. The high-refractive indexlayer 119, the relation of the refractive index difference, and theoptical path will be described later.

The shape of the concave lens portion 117 is not particularly limited aslong as it can converge the optical path of the image light in the abovedirection closer to the direction normal to the front face. Examples ofthe shape include: spherical shape and nonspherical shape. The pitch ofthe concave lens portion 117 is preferably 30-100 μm.

Other elements of the light-transmissive portion 113 are in common withthe light-transmissive portion 63 of the optical sheet 60, so thedescriptions will be omitted.

The light-absorbing portion 114 is also in common with theabove-described light-absorbing portion 64, so the description will beomitted.

Next, the high-refractive index layer 119 will be described. Thehigh-refractive index layer 119 is laminated on the face of theabove-described optical functional layer 112 where the concave lensportion 117 is formed and has protrusions corresponding to the shape ofconcave lens portion 117; thereby the high-refractive index layer 119can form an interface between the concave lens portion 117 and thehigh-refractive index layer 119. The refractive index of thehigh-refractive index layer 119 is refractive index N_(k) which islarger than at least the refractive index N_(p), of thelight-transmissive portion 113. Accordingly, as described below, it ispossible to more adequately control the optical path of the image lightto the front face side by the concave lens portion 117. Thehigh-refractive index layer 119 is preferably made of a material havinga refractive index of 1.6 or more; the material is preferably, forexample, a zirconia-based or a florene-based material (manufactured byOsaka Gas Chemicals Co., Ltd.).

According to the image source unit 104, it has an adequate layerstructure suitable for the image display unit of, for example, plasmatelevision, thereby it is possible to improve the front brightness. Inthis case, concave lens portion 117 of the optical functional layer 112is arranged so that it faces the observer side. In FIG. 12, examples ofthe optical paths are shown.

The image light L11 is a light emitted from the image light source andtransmitted in parallel with the normal direction of the sheet. Sincethe image light L11 passes through the deepest part of the concave lensportion 117, the light is transmitted to the front face withoutrefraction.

The image lights L12 and L13 are image lights which respectively enterinto the light-transmissive portion 113 at a certain angle with respectto the normal direction of the sheet. By the effect of the concave lensportion 117, such image lights L12 and L13 are refracted so that therefracted light has an angle closer to the normal direction of thesheet; and the refracted image lights L12 and L13 are outputted.

On the other hand, the external light L14 enters into thelight-absorbing portion 114 and absorbed by the light-absorbingparticles existing in the light-absorbing portion 114. Because of this,it is possible to improve the contrast.

EXAMPLES

Hereinafter, the present invention will be more specifically described.However, the invention is not limited by the Examples.

Example 1 (1) Preparation of a Composition for Constituting theLight-Transmissive Portion

To a reactor, 40.0 parts by mass of bisphenol A-ethylene oxide 2mole-adduct, 15.0 parts by mass of isophorone diisocyanate, and 0.02parts by mass of bismuth tri(2-ethyl hexanoate) (50% solution of 2-ethylhexanoic acid) as urethanizing catalyst were added and reacted at 80° C.for 5 hours; then, 5.0 parts by mass of 2-hydroxyethyl acrylate wasadded and reacted at 80° C. for 5 hours, to obtain a light-curableprepolymer (P1).

Then, 60.0 parts by mass of the light-curable prepolymer (P1), 15.0parts by mass of phenoxyethyl acrylate as a reactive diluent monomer(M1), 25.0 parts by mass of diacrylate of bisphenol A-ethylene oxide 4mole-adduct, 0.05 parts by mass of phosphate ester oftetradecanol-ethylene oxide 10 mole-adduct (as a mold release agent;monoester/diester=1/1 by mole ratio), 0.05 parts by mass of stearylamineethylene oxide 15 mole-adduct, and 3.0 parts by mass of1-hydroxycyclohexyl phenyl ketone (commodity name: “IRGACURE 184”manufactured by Ciba Speciality Chemicals) as a photopolymerizationinitiator (I1) were mixed and homogenized, to obtain a composition forconstituting the light-transmissive portion.

The composition for constituting the light-transmissive portion thusobtained was applied with a thickness of 100 μm and cured by irradiatingultraviolet having an intensity of 800 mJ/cm² by using a high-pressuremercury vapor lamp. The refractive index of the cured composition at 589nm measured by the Multiwavelength Abbe Refractometer (“DR-M4”manufactured by Atago Co., Ltd.) is 1.550.

(2) Base Material

As the base material, a polyethylene terephthalate (PET) film (commodityname: A4300, manufactured by Toyobo Co., Ltd., thickness: 100 μm) wasused.

(3) Production of Die Roll

A die roll to be used for producing the optical functional layer wasproduced. The die roll is cylindrical and got plated with copper; thecopper-plated portion was cut by turning tool (it may also be called“bite”.) to form grooves having a shape corresponding to the shape ofthe light-transmissive portion. As the turning tool, a diamond bite wasused. The tip of the diamond bite is shown in FIG. 13. A part of thebite from the tip to the level of 6 μm away from the tip has anoutwardly projecting curved face; the width of the bite at the level of6 μm away from the tip is 35 μm. The obliquity angle of the bite is 1.9°and the width of the bite at the level of 85 μm away from the tip is 41μm.

By using the diamond bite and setting the intergroove pitch to 45 μm inthe roll-axis direction, outer circumference of the copper-plated dieroll was cut to form the grooves. Consequently, the grooves individuallyhad a substantially trapezoid shape of which part from the 85 μm-deepbottom to the 6 μm-deep level had a curved face projecting toward thedie roll side, of which width from the bottom to the 6 μm-deep level was35 μm, and the width of the die roll surface side (i.e. at the level of85 μm away from the bottom of the groove) was 41 μm. The cut roll wasplated with chromium.

(4) Formation of the Light-Transmissive Portion

The base material of the above description (2) was fed between a niproll and the die roll produced in accordance with the above description(3). At the same time, the composition for constituting thelight-transmissive portion obtained in accordance with the description(1) was supplied from the feeder onto the base material layer; and thenthe composition for constituting the light-transmissive portion isfilled between the base material layer and the die roll by pressuregiven between the die roll and the nip roll. Later, the composition forconstituting the light-transmissive portion was cured by irradiatingultraviolet having an intensity of 800 mJ/cm² by a high-pressure mercuryvapor lamp from the base material side to form the light-transmissiveportion. Then, thus formed light-transmissive portion was released fromthe die roll by using mold-releasing nip, a sheet (i.e. an intermediatemember) containing the light-transmissive portions and having athickness of 205±20 μm was formed.

The elastic modulus of the light-transmissive portion was measured bypressuring (loading) a microindenter and removing the pressure by acompression microhardness tester (FISCHER HM2000). The load was 100 mN,loading velocity was 4 μm/10 seconds, and the holding time was 60seconds. As a result, the elastic modulus of the light-transmissiveportion was 800 MPa.

The shape of the light-transmissive portion at this phase wascorresponding to the shape of the grooves of the die roll. Hence, thelight-transmissive portion had protrusions having a height of about 6 μmalong the opposite side of the base material layer.

(5) Preparation of the Composition for Constituting the Light-AbsorbingPortion

In a reactor, 20.0 parts by mass of oxirane,2,2′-[(1-methylethylidene)bis(4,1-phenyleneoxymethyl ene)]bis-,homopolymer, 2-propenoate, as light-curable prepolymers (P2); 20.0 partsby mass of 2-phenoxyethyl acrylate, 20.0 parts by mass ofα-acryloyl-ω-phenoxy poly(oxyethylene), and 13.0 parts by mass of2-{2-[2-(acryloyloxy)(methyl)ethoxy] (methyl)ethoxy}(methyl) ethylacrylate, as a reactive diluent monomer (M2); 20.0 parts by mass ofacrylic cross-linked particulate (manufactured by Ganz Chemical Co.,Ltd.) containing 25% carbon black having an average diameter of 4.0 μmas a light-absorbing particle; and 7.0 parts by mass of1-hydroxycyclohexyl phenyl ketone (“IRGACURE 184” manufactured by CibaSpeciality Chemicals) as a photopolymerization initiator (I2) were mixedand homogenized, to obtain a composition for constituting thelight-absorbing portion.

The composition obtained by removing the light-absorbing particle fromthe composition for constituting the light-absorbing portion was appliedwith a thickness of 10 μm and cured by irradiating ultraviolet having anintensity of 800 mJ/cm² by using a high-pressure mercury vapor lamp. Therefractive index of the cured composition at 589 nm measured by theMultiwavelength Abbe Refractometer (“DR-M4” manufactured by Atago Co.,Ltd.) is 1.547.

(6) Formation of the Light-Absorbing Portion

The composition for constituting the light-absorbing portion obtained inaccordance with the description (5) was supplied on the intermediatemember obtained in accordance with the description (4) from the feeder.Then, by using a doctor blade which was arranged in a directionsubstantially perpendicular to the moving direction of the intermediatemember, the composition for constituting the light-absorbing portionthus supplied on the intermediate member was filled in the substantiallyV-shape grooves formed in the intermediate member (i.e. grooves betweenthe light-transmissive portion) and the excessive amount of thecomposition for constituting the light-absorbing portion was strickled.Then, the remaining composition for constituting the light-absorbingportion was cured by irradiating ultraviolet having an intensity of 800mJ/cm² by using a high-pressure mercury vapor lamp to form thelight-absorbing portions (This process may be called “the firstfilling”.). In this state, recess portions having a depth of 6 μmoccurred on the surface of the light-absorbing portion.

(7) Preparation and Formation of the Covering Layer

In this Example, for the purpose of reducing the degree of the recess ofthe light-absorbing portion, covering layers were formed on therespective light-absorbing portion.

The preparation of the covering layer is as follows. In a reactor, 42.0parts by mass of urethane acrylate and 18.0 parts by mass of epoxyacrylate oligomer as photopolymerization component; 35.0 parts by massof tripropylene glycol diacrylate and 5.0 parts by mass of methoxytriethylene glycol acrylate as a light-curable monomer; 7.0 parts bymass of 1-hydroxycyclohexyl phenyl ketone (commodity name: “IRGACURE184” manufactured by Ciba Speciality Chemicals) as a photopolymerizationinitiator were mixed and homogenized to obtain the composition for thecovering layer.

The composition was applied with a thickness of 10 μm and cured byirradiating ultraviolet having an intensity of 800 mJ/cm² by using ahigh-pressure mercury vapor lamp. The refractive index of the curedcomposition at 589 nm measured by the Multiwavelength Abbe Refractometer(“DR-M4” manufactured by Atago Co., Ltd.) is 1.490.

The composition thus obtained was supplied from the feeder on theintermediate member obtained in accordance with the description (6).Then, by using a doctor blade which was arranged in a directionsubstantially perpendicular to the moving direction of the intermediatemember, the composition for forming the covering layer thus supplied onthe intermediate member was filled in the recess portion of thelight-absorbing portion and the excessive amount of the composition wasstrickled (This process may be called “second filling”.).

Then, the composition for constituting the light-absorbingportioncovering layer was cured by irradiating ultraviolet having anintensity of 800 mJ/cm² by using a high-pressure mercury vapor lamp. Inthis state, recess portions having a depth of 2 μm occurred on thesurface of the light-absorbing portion.

It should be noted that the refractive index of the covering layer wasset to the same as the refractive index of the adhesive layer; so, theabove-described refraction of the light occur at an interface betweenthe covering layer and the recess portion of the first filling.Therefore, “the recess portion of the light-absorbing portion” in thiscontext has the depth occurred at the time of the first filling.

(8) Formation of the Adhesive Layer

The adhesive layer was obtained by mixing: 100 parts by mass of anacrylic resin adhesive (commodity name: “SK dyne 2094” manufactured bySoken Chemical & Engineering Co., Ltd., solid content: 25.0 mass %,solvent: ethyl acetate and methylethyl ketone); 0.28 parts by mass of acrosslinking agent (commodity name: “E-5XM”, “L-45”, manufactured bySoken Chemical & Engineering Co., Ltd., solid content: 5.0 mass %); 0.25parts by mass of 1,2,3-benzotriazole; and 32.0 parts by mass of dilutingsolvent (toluene/methylethyl ketone/cyclohexanone=27.69 g/27.69 g/4.61g).

The composition was applied on a mold release film (“E 7007”manufactured by Toyobo Co., Ltd., thickness: 38 μm) and dried; then, thedried composition was stuck together with the optical functional layer.

The refractive index of the adhesive layer at 589 nm measured by theMultiwavelength Abbe Refractometer (“DR-M4” manufactured by Atago Co.,Ltd.) is 1.490.

The storage elastic modulus of the adhesive layer is 0.22 MPa.

In this way, the optical sheet of Example 1 was produced.

Example 2

In Example 2, shape of the grooves of the die roll was changed so as tomake the protrusion of the light-transmissive portion having a height of3 μm. Other than this, Example 2 was carried out in the same manner asExample 1.

Example 3

In Example 3, a material having light-transmissive portions of whichelastic modulus is 2000 MPa was used. The details are as follows.

In a reactor, 40.0 parts by mass of diacrylate of bisphenol-A diglycidylether, 10.0 parts by mass of diacrylate of bisphenol A-ethylene oxide 4mole-adduct, 10.0 parts by mass of a mixture of pentaacrylate andhexaacrylate of dipentaerythritol (mass ratio: 60/40) as a light-curableprepolymer (P1); 0.05 parts by mass of phosphate ester oftetradecanol-ethylene oxide 10 mole-adduct (monoester/diester=1/1 bymole ratio) and 0.05 parts by mass of stearyl amine-ethylene oxide 15mole-adduct as a mold release agent (S1); and 3.0 parts by mass of1-hydroxycyclohexyl phenyl ketone (commodity name: “IRGACURE 184”manufactured by Ciba Speciality Chemicals) as a photopolymerizationinitiator were mixed and homogenized, to obtain the composition forconstituting the light-transmissive portion.

The shape of the light-transmissive portion was the same as that ofExample 1. The recess portion of the light-absorbing portion after thefirst filling had a depth of 3 μm; and the recess portion after thesecond filling had a depth of 1 μm.

Example 4

In Example 4, a material having light-transmissive portions of whichelastic modulus is 1500 MPa was used. The details are as follows.

In a reactor, 5.0 parts by mass of diacrylate of bisphenol-A diglycidylether as a light-curable prepolymer (P1); 40.0 parts by mass ofphenoxyethyl acrylate, 45.0 parts by mass of diacrylate of bisphenolA-ethylene oxide 4-mole adduct and 10.0 parts by mass of a mixture ofpentaacrylate/hexaacrylate of dipentaerythritol (mass ratio: 60/40), asreactive diluent monomers (M1); 0.05 parts by mass of phosphate ester oftetradecanol-ethylene oxide 10-mole adduct (monoester/diester=1/1 bymole ratio) and 0.05 parts by mass of stearyl amine-ethylene oxide 15mole-adduct as a mold release agent (S1); 3.0 parts by mass of1-hydroxycyclohexyl phenyl ketone (commodity name: “IRGACURE 184”manufactured by Ciba Speciality Chemicals) as a photopolymerizationinitiator (I1) were mixed and homogenized, to obtain the composition forconstituting the light-transmissive portion.

The shape of the light-transmissive portion was the same as that ofExample 1. The recess portion of the light-absorbing portion after thefirst filling had a depth of 4 μm; and the recess portion after thesecond filling had a depth of 1.5 μm.

Example 5

In Example 5, a material having light-transmissive portions of whichelastic modulus is 500 MPa was used. The details are as follows.

In a reactor, 10.0 parts by mass of diacrylate of bisphenol A diglycidylether as a light-curable prepolymer (P1); 50.0 parts by mass ofphenoxyethyl acrylate, 30.0 parts by mass diacrylate of bisphenolA-ethylene oxide 4-mole adduct, and 10.0 parts by mass of a mixture ofpentaacrylate/hexaacrylate of dipentaerythritol (mass ratio: 60/40) as areactive diluent monomer (M1); 0.05 parts by mass of phosphate ester oftetradecanol-ethylene oxide 10-mole adduct (monoester/diester=1/1 bymole ratio) and 0.05 parts by mass of stearyl amine-ethylene oxide 15mole-adduct as a mold release agent (S1); 3.0 parts by mass of1-hydroxycyclohexyl phenyl ketone (commodity name: “IRGACURE 184”manufactured by Ciba Speciality Chemicals) as a photopolymerizationinitiator (I1) were mixed and homogenized, to obtain the composition forconstituting the light-transmissive portion.

The shape of the light-transmissive portion was the same as that ofExample 1. The recess portion of the light-absorbing portion after thefirst filling had a depth of 6.0 μm; and the recess portion after thesecond filling had a depth of 3.0 μm.

Example 6

In Example 6, a material of which light-transmissive portions has anelastic modulus of the obtained of 20 MPa was used. The details are asfollows.

In a reactor, 10.0 parts by mass of 2,4-tolylene diisocyanate, 0.03parts by mass of dilauryl di-n-butyl acid, 0.01 parts by mass of2,6-di-t-butyl-p-cresol, 10.0 parts by mass of 2-hydroxyethyl acrylate,and 20.0 parts by mass of polytetramethylene glycol were mixed to obtaina light-curable prepolymer (P1).

Then, 40.0 parts by mass of the light-curable prepolymer (P1) thusobtained; 30.0 parts by mass of phenoxy tetraethylene glycol acrylate,20.0 parts by mass of acrylate of p-cumylphenol-ethylene oxide 2-moleadduct, and 10.0 parts by mass of dipentaerythritol hexaacrylate asreactive diluent monomers (M1); 0.05 parts by mass of phosphate ester oftetradecanol-ethylene oxide 10-mole adduct (monoester/diester=1/1 bymole ratio) and 0.05 parts by mass of stearyl amine-ethylene oxide15-mole adduct, as mold release agents (S1); 3.0 parts by mass of1-hydroxycyclohexyl phenyl ketone (commodity name: “IRGACURE 184”manufactured by Ciba Speciality Chemicals) as a photopolymerizationinitiator (I1) were mixed and homogenized to obtain the composition forconstituting the light-transmissive portion.

The shape of the light-transmissive portion was the same as that ofExample 1. The recess portion of the light-absorbing portion after thefirst filling had a depth of 8 μm; and the recess portion after thesecond filling had a depth of 5 μm.

Example 7

In Example 7, a material of which light-transmissive portions have anelastic modulus of 2500 MPa was used. The details are as follows.

In a reactor, 40.0 parts by mass of diacrylate of bisphenol A diglycidylether as a light-curable prepolymer (P1); 50.0 parts by mass ofphenoxyethyl acrylate and 10.0 parts by mass of a mixture ofpentaacrylate/hexaacrylate of dipentaerythritol (mass ratio: 60/40), asreactive diluent monomers (M1); 0.05 parts by mass of phosphate ester oftetradecanol-ethylene oxide 10-male adduct (monoester/diester=1/1 bymole ratio) and 0.05 parts by mass of stearyl amine-ethylene oxide 15mole-adduct as mold release agents (S1); 3.0 parts by mass of1-hydroxycyclohexyl phenyl ketone (commodity name: “IRGACURE 184”manufactured by Ciba Speciality Chemicals) as a photopolymerizationinitiator (I1) were mixed and homogenized, to obtain the composition forconstituting the light-transmissive portion.

The shape of the light-transmissive portion was the same as that ofExample 1. The recess portion of the light-absorbing portion after thefirst filling had a depth of 2 μm; and the recess portion after thesecond filling had a depth of 0.4 μm.

Example 8

In Example 8, a material of which light-transmissive portions have amelastic modulus of 9.0 MPa was used. The details are as follows.

In a reactor, 10.0 parts by mass of 2,4-tolylene diisocyanate, 0.03parts by mass of dilauryl di-n-butyl acid, 0.01 parts by mass of2,6-di-t-butyl-p-cresol, 10.0 parts by mass of 2-hydroxyethyl acrylate,and 20.0 parts by mass of polytetramethylene glycol were mixed to obtaina light-curable prepolymer (P1).

Then, 40.0 parts by mass of the light-curable prepolymer (P1) thusobtained; 15.0 parts by mass of phenoxyethyl acrylate, 15.0 parts bymass of phenoxy tetraethylene glycol acrylate, and 20.0 parts by mass ofacrylate of p-cumylphenol-ethylene oxide 2-mole adduct as reactivediluent monomers (M1); 0.05 parts by mass of phosphate ester oftetradecanol-ethylene oxide 10-mole adduct (monoester/diester=1/1 bymole ratio) and 0.05 parts by mass of stearyl amine-ethylene oxide15-mole adduct as mold release agents (S1); 3.0 parts by mass of1-hydroxycyclohexyl phenyl ketone (commodity name: “IRGACURE 184”manufactured by Ciba Speciality Chemicals) as a photopolymerizationinitiator (I1); and 10.0 parts by mass of other tetra ethylene glycoldiacrylate were mixed and homogenized to obtain the composition forconstituting the light-transmissive portion.

The shape of the light-transmissive portion was the same as that ofExample 1. The recess portion of the light-absorbing portion after thefirst filling had a depth of 9 μm; and the recess portion after thesecond filling had a depth of 6.5 μm.

Example 9

In Example 9, an optical sheet which had an adhesive layer formed on therecess portion side of the optical functional layer was formed, whereinthe adhesive composition for forming the adhesive layer had a storageelastic modulus of 0.14 MPa. Except for the adhesive layer, componentsof Example 9 are the same as those of Example 1. The details of theadhesive layer are as follows.

To 300 parts by mass of ethyl acetate, 50.0 parts by mass of n-butylacrylate, 30.0 parts by mass of methyl acrylate, 19.5 parts by mass ofmethyl methacrylate, 0.5 parts by mass of 2-hydroxyethyl acrylate, 0.2parts by mass of azobisisobutyronitrile as an initiator were added andstirred at 60° C. for 12 hours to obtain an acrylic acid ester copolymersolution.

Then, based on 100 parts by mass of solid portion of the obtainedcopolymer solution, 0.5 parts by mass of isocyanate-based crosslinkingagent, i.e. “TD-75” (manufactured by Soken Chemical & Engineering Co.,Ltd.) as a crosslinking agent was added and the mixture was diluted with2-butanone to be a solution having a concentration of 25 mass %, toobtain an adhesive solution.

The solution was applied with a thickness of 25 μm on a mold releasefilm (“E 7007” manufactured by Toyobo Co., Ltd., thickness: 38 μm) anddried; further, another mold release film (“E 7006” manufactured byToyobo Co., Ltd., thickness: 38 μm) was stuck thereon to form anon-carrier adhesive film.

Example 10

In Example 10, an optical sheet which had an adhesive layer formed onthe recess portion side of the optical functional layer was formed,wherein an adhesive composition for forming the adhesive layer had astorage elastic modulus of 0.78 MPa. Except for the adhesive layer,components of Example 10 are the same as those of Example 1. Theformation of the adhesive layer will be described as follows.

To 300 parts by mass of ethyl acetate, 50.0 parts by mass of n-butylacrylate, 30.0 parts by mass of methyl acrylate, 0.5 parts by mass of2-hydroxyethyl acrylate, 19.5 parts by mass of dimethyl acrylamide, 0.2parts by mass of azobisisobutyronitrile as an initiator, were added andstirred at 60° C. for 12 hours to obtain acrylic acid ester copolymersolution.

Then, based on 100 parts by mass of solid portion of the copolymersolution, 0.5 parts by mass of isocyanate-based crosslinking agent, i.e.“TD-75” (manufactured by Soken Chemical & Engineering Co., Ltd.) as acrosslinking agent was added and the mixture was diluted with 2-butanoneto be an adhesive solution having a concentration of 25 mass %, toobtain an adhesive solution.

The solution was applied with a thickness of 25 μm on a mold releasefilm (“E 7007” manufactured by Toyobo Co., Ltd., thickness: 38 μm) anddried; further, another mold release film (“E 7006” manufactured byToyobo Co., Ltd., thickness: 38 μm) was stuck thereon to form anon-carrier adhesive film.

Example 11

In Example 11, an optical sheet which had an adhesive layer formed onthe recess portion side of the optical functional layer was formed,wherein an adhesive composition for forming the adhesive layer had astorage elastic modulus of 0.09 MPa. Except for the adhesive layer,components of Example 11 are the same as those of Example 1. Theformation of the adhesive layer will be described as follows.

To 300 parts by mass of ethyl acetate, 75.0 parts by mass of n-butylacrylate, 20.0 parts by mass of methyl acrylate, 5.0 parts by mass of2-hydroxyethyl acrylate, 0.2 parts by mass of azobisisobutyronitrile asan initiator were added and stirred at 60° C. for 12 hours to obtain anacrylic acid ester copolymer solution.

Then, based on 100 parts by mass of solid portion of the copolymersolution, 0.5 parts by mass of isocyanate-based crosslinking agent, i.e.“TD-75” (manufactured by Soken Chemical & Engineering Co., Ltd.) as acrosslinking agent was added and the mixture was diluted with 2-butanoneto be a solution having a concentration of 25 mass to obtain an adhesivesolution.

The solution was applied with a thickness of 25 μm on a mold releasefilm (“E 7007” manufactured by Toyobo Co., Ltd., thickness: 38 μm) anddried; further, another mold release film (“E 7006” manufactured byToyobo Co., Ltd., thickness: 38 μm) was stuck thereon to form anon-carrier adhesive film.

Example 12

In Example 12, an optical sheet which had an adhesive layer formed onthe recess portion side of the optical functional layer was formed,wherein an adhesive composition for forming the adhesive layer had astorage elastic modulus of 1.1 MPa. Except for the adhesive layer,components of Example 12 are the same as those of Example 1. Theformation of the adhesive layer will be described as follows.

To 300 parts by mass of ethyl acetate, 45.0 parts by mass of n-butylacrylate, 30.0 parts by mass of methyl acrylate, 0.5 parts by mass of2-hydroxyethyl acrylate, 24.5 parts by mass of N,N-dimethyl acrylamide,0.2 parts by mass of azobisisobutyronitrile as an initiator were addedand stirred at 60° C. for 12 hours to obtain an acrylic acid estercopolymer solution.

Then, based on 100 parts by mass of solid portion of the copolymersolution, 0.5 parts by mass of isocyanate-based crosslinking agent, i.e.“TD-75” (manufactured by Soken Chemical & Engineering Co., Ltd.) as acrosslinking agent was added and the mixture was diluted with 2-butanoneto be a solution having a concentration of 25 mass %, to obtain anadhesive solution.

The solution was applied with a thickness of 25 μm on a mold releasefilm (“E 7007” manufactured by Toyobo Co., Ltd., thickness: 38 μm) anddried; further, another mold release film (“E 7006” manufactured byToyobo Co., Ltd., thickness: 38 μm) was stuck thereon to form anon-carrier adhesive film.

Example 13

In Example 13, an optical sheet of Example 1 in which recess portions ofthe light-absorbing portion were disappeared by the first filling wasformed. Specifically, so as not to form the recess portion, the amountof the composition for constituting the light-absorbing portion to bestrickled was reduced by lowering strickling pressure of the doctorblade.

Comparative Example

In Comparative example, a die roll was produced with cutting bites(cutting tip) which do not have projecting curved portion in the tip;then, a light-transmissive portion was obtained. Other than the dieroll, conditions of Comparative example are the same as those ofExample 1. The optical sheet of Comparative example is a conventionaloptical sheet.

With respect to the above Examples 1-13 and Comparative example, anoriginal optical sheet adhered in the plasma displays (commodity name:“VIERA G2”, 50 inch-wide, manufactured by Panasonic corporation) werepeeled and the optical sheets of Examples and Comparative example wererespectively stocked to the plasma displays. The protrusion of thelight-transmissive portion was arranged so that it faces the PDP side.Then, the total white brightness at respective view angles were measuredin a darkroom. The total white brightness in the darkroom when nooptical sheet was adhered in the plasma display was 140 cd/m². A part ofthe conditions of each optical sheet is shown in Table 1 and themeasurement results of the brightness are shown in Table 2.

TABLE 1 Height of Pro- Depth of Recess Depth of Recess trusion of Light-portion of Light- portion of Light- Elastic modulus Storage elastictransmissive absorbing portion absorbing portion of Light-absorbingmodulus of portion (1st filling) (2nd filling) portion Adhesive layer(μm) (μm) (μm) (MPa) (MPa) Example 1 6 6.0 2.0 800 0.22 Example 2 3 6.02.0 800 0.22 Example 3 6 3.0 1.0 2000 0.22 Example 4 6 4.0 1.5 1700 0.22Example 5 6 6.0 3.0 500 0.22 Example 6 6 8.0 5.0 20 0.22 Example 7 6 2.00.4 2500 0.22 Example 8 6 9.0 6.5 9 0.22 Example 9 6 6.0 2.0 800 0.14Example 10 6 6.0 2.0 800 0.78 Example 11 6 6.0 2.0 800 0.09 Example 12 66.0 2.0 800 1.1 Example 13 6 0.0 — 800 0.22 Comparative 0 6.0 2.0 8000.22 example

TABLE 2 Brightness of each View angle (cd/m²) View View View View Viewangle angle angle angle angle 0° 15° 30° 45° 60° Example 1 118.2 86.154.5 29.9 18.1 Example 2 118.9 86.2 54.6 29.9 18.3 Example 3 117.1 84.951.7 27.5 17.3 Example 4 117.9 85.5 52.7 28.3 17.7 Example 5 118.2 86.154.5 29.9 18.1 Example 6 123.2 87.9 56.7 32.7 19.4 Example 7 115.4 84.851.6 26.9 17.2 Example 8 125.2 88.7 58.0 33.9 19.7 Example 9 118.2 86.154.5 29.9 18.1 Example 10 118.2 86.1 54.5 29.9 18.1 Example 11 118.286.1 54.5 29.9 18.1 Example 12 118.2 86.1 54.5 29.9 18.1 Example 13118.2 86.1 54.5 29.9 18.1 Comparative 114.4 83.4 51.3 26.6 17.0 example

As seen from Tables 1 and 2, The optical sheets of whichlight-transmissive portion has protrusions exhibited higher brightnesscompared with Comparative example at each view angle, thereby improvedthe use efficiency of the light. Degree of brightness seen from aposition normal to the front face (i.e. view angle: 0°) is particularlylarge, and front brightness can be improved.

In Example 7 where the elastic modulus of the light-transmissive portionis high, the light-transmissive portion was hard, so that it tended tobe broken during production; thereby the production was difficult. Onthe other hand, in Example 8 where the elastic modulus of thelight-transmissive portion is low, the light-transmissive portion wassoft, so that recess portion became larger when forming thelight-absorbing portion. Therefore, there is a problem in productionsuch that bubbles tend to be easily included when forming the adhesivelayer.

In Example 11 where the storage elastic modulus of the adhesivecomposition is low, the adhesive composition of the adhesive layer wassoft, so that problems of the recess distortion tended to occur; therebythere is a problem in production of an optical filter in good quality.In Example 12 where the storage elastic modulus of the adhesivecomposition is high, the adhesive composition of the adhesive layer washard, so that the adhesive layer was not well-embedded in the opticalfunctional layer face; thereby bubbles tended to be included, whichresulted in poor appearance. In other Examples, the adhesive layer waswell-embedded in the optical functional layer face and no recessdistortion occurred by foreign materials during the production process;overall, optical sheets in good quality were easily produced.

1. An image source unit comprising: an image light source; and an optical sheet laminated on the image light source, the optical sheet comprising: a base material layer; and an optical functional layer formed on the image light source side surface of the base material layer, the optical functional layer comprising: light-transmissive portions arranged parallel in a light transmissive manner along the sheet face; and light-absorbing portions arranged in a light absorbing manner between the light-transmissive portions, the image light source side face of the light-transmissive portion having protrusions each having a curved or polygonal line so that the protrusions project towards the image light source side in cross section in the sheet-thickness direction.
 2. The image source unit according to claim 1, wherein an adhesive layer having a refractive index which is lower than that of the light-transmissive portion is laminated on an image light source side face of the optical functional layer.
 3. The image source unit according to claim 1, wherein the image light source side face of the light-absorbing portion has a recess portion so that the bottom of the recess portion faces the opposite side from the image light source and formed in curved or polygonal manner in cross section in the sheet-thickness direction.
 4. The image source unit according to claim 3, wherein the depth of the recess portion of the light-absorbing portion is in the range of 0.5-6 μm.
 5. The image source unit according to claim 1, wherein the image light source side of the light-absorbing portion is covered with a covering layer.
 6. The image source unit according to claim 1, wherein the elastic modulus of the light-transmissive portion is 10 MPa or more and below 2000 MPa.
 7. The image source unit according to claim 2, wherein the storage elastic modulus of an adhesive for forming the adhesive layer is 0.1 MPa or more and below 0.8 MPa.
 8. The image source unit according to claim 7, wherein the thickness of the adhesive layer is 20 μm or more and 50 μm or less.
 9. The image source unit according to claim 1, wherein the optical sheet has an antireflection layer or an anti-glare layer located on its surface opposite to the light source.
 10. The image source unit according to claim 1 further comprising a wavelength filter layer for controlling transmissivity of a light having a certain wavelength.
 11. The image source unit according to claim 1 further comprising an electromagnetic wave shielding layer for shielding electromagnetic waves.
 12. An image display unit comprising the image source unit according to claim
 1. 